current trends in scada systems situational …...1 graham nasby, p.eng, pmp, cap water scada &...

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Graham Nasby, P.Eng, PMP, CAP

Water SCADA & Security Specialist

City of Guelph Water Services

Current Trends in SCADA Systems

Situational AwarenessAlarm Management

Data AvailabilitySystem Robustness/Redundancy

OWWA Total Water Solutions Workshop

Tuesday, Oct 3, 2017 – Timmins, Ontario, Canada

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About the Speaker

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Graham Nasby , P.Eng., PMP, CAPWater SCADA & Security Specialist City of Guelph Water Services

• 10 years in the consulting sector• Joined Guelph Water Services in 2015

• OWWA and WEAO Member, Member of OWWA Automation Committee• Co-chair of ISA112 SCADA Systems standards committee• Voting member of ISA101 HMI Design standards committee• Voting member of ISA18 Alarm Management standards committee• Named Canadian Expert on IEC/SCC-TC65 with Standards Council of Canada

• Has published over 30 papers and articles on automation topics• Received University of Guelph “Mid Career Achievement Award” in 2014• Named ISA’s technical division leader of the year award in 2013.

• Contact: [email protected]

Current SCADA Trends

OWWA Oct 3, 2017 – Timmins, Ontario, Canada

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City of Guelph Water Services

• Guelph, Ontario, Canada

• 130,000 residents

• 21 groundwater wells

• 3 water towers

• 549 km of water mains

• 49,000 service connections

• 2,750 fire hydrants

• 46,000 m3/day [12 MGD]

3Current SCADA Trends


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Presentation Outline

• Review of what SCADA is

• State of Most SCADA Systems

• Situational Awareness

• High Performance HMI

• Alarm Management

• Data Redundancy – making it easier

• SCADA communication networks

• Cyber Security

• Planning for SCADA Upgrades: building on what you have



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Review: What is SCADA?

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SCADA = Supervisory Control and Data AcquisitionCurrent SCADA Trends


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Typical SCADA Architecture

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Why we have SCADA systems

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• Unattended automatic control of water facilities

• Logging of critical control parameters

– Chlorine Residuals (e.g., 5 minute recording intervals)

– Turbidity

– Well Flow Rates & Daily Flow Totals

– POE Flow Rates & Daily flow Totals

– Tower Levels & Pressure

• Provides “visualization” of water facilities to Operators

• Enables remote monitoring and control by Operators

• Triggering and Annunciation of Alarms

• Automated responses (increase chlorine dose, shutdown, etc.)

• Reporting based on logged process data



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What’s new in SCADA?

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• Is anything abnormal?• What if your are colour blind?

• What is running?• Is the process running well?



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SCADA: Situational Awareness

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To be an effective operator –

you have to be aware of what your plant is doing



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Common SCADA problem

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In some SCADA systems….You can’t see the whole picture



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Common SCADA problem

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What your SCADA system may not be showing you



12

12

CAN

YOU

FIND

THE

PROBLEM

ON THE

SCADA

SCREEN?



13

13

Friendly SCADA Guy



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Situational Awareness

• To be able to react to a problem,

Operators need to be aware of the problem

• Old way operating “by alarm” (reactively)

• New approach: Present data to operators so they can proactively

respond to problems as they develop

• Reserve alarms only for events that require immediate action

• High Performance HMIs (Human Machine Interfaces)

• Alarm Management (better designed alarm systems)



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High Performance HMIs



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High Performance HMIs

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HMI = Human Machine Interface (computer screen)

Poor Colour Scheme

High Performance HMI

Colour scheme



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High Performance HMI – Plant Running Normally

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Notice the

Lack of Colour

HI

LO

F



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High Performance HMI – Showing Pump Statuses

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Red/Green

for status

vs.

Greyscale &

redundant

coding

Pumps not monitored by SCADA (no status information) are just shown as mid-gray:

Not Running

Running

STOPPED

RUNNING

L

AA

L



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High Performance HMI – Analog Values

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Diagnostic Priority

Priority 3 Priority 2 Priority 1

480.1 psi 480.1 psi 480.1 psi480.1 psi

2 1

Diagnostic Priority


480.1 psi 480.1 psi 480.1 psi480.1 psi4 3

Better

Betterer

Best!Suppressed

Alarm

480.1 psiS

480.1 psi No Alarm Indication 480.1 psiOftenSeen

Only a ColourChange!

Show alarms in multiple ways: Colour, Shape, Text (“redundant coding”)

480.1 psi 480.1 psi480.1 psi 480.1 psi

Diagnostic Priority




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High Performance HMI – Analog Values Another Way

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Coolgpm

RECYCLE COMPRESSOR K43

Alarm Indicator

Desirable

Operating Range

Alarm Range

Alarm Range

Show Values Show Trends

Buttons for additional functionality

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Suctpsig

Interpsig

Dschpsig

SuctdegF

InterdegF

DschdegF

E. Vibmil

N. Vibmil

W. Vibmil

MotorAmps

Oilpsig

OildegF

42.7

38.793.1

18595 120

170

128

9170

80

290

Interlock

Indicator



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High Performance HMI – Tank Levels Depiction



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High Performance HMI – Embedding Trends

22Source: High Performance HMI Handbook



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High Performance HMI – Display Hierarchy

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• HIERARCHY for Displays:

• Level 1 – Plant or Entire System Overview

– Entire Operator Span of Control. “Single-Glance”

• Level 2 – Sub-Process Overview

– More details than a Level 1 display, smaller area

• Level 3 – Equipment or Details Screen

– Specific details about part of the process or control

• Level 4 – Specific Task or Diagnostic Screen

– Very detailed screen, only used for diagnostics



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High Performance HMI – The old way

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R77

N28

Farnam 6

C16

Marcum

CSX9

Tempe

Adams 3



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High Performance HMI – Proper Level 1 Display



Source: High Performance HMI Handbook

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High Performance HMI – ISA101 Standard

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DESIGNSYSTEM

STANDARDS

OPERATEIMPLEMENT

CONTINUOUS WORK PROCESSES

Continuous Improvement

Philosophy

Style Guide

Toolkits

In Service

Maintain

Decommission

Continuous Improvement

Build Displays

Build Console

Test

Train

Commission

Verification

Console Design

HMI System Design

User, Task, Functional

Requirements

Display Design

New DisplayDisplay Changes

New SystemMajor Changes

ENTRYENTRY

MOC Audit Validation



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Alarm Management



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Alarm Management: ISA18.2

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ANSI/ISA-18.2-2016 *

Management of Alarm Systems for the Process Industries

Alarm: An audible and/or visible means of indicating to the operator an

equipment malfunction, process deviation or abnormal condition requiring a

timely response.

Methodology for identifying, rationalizing and designing alarms to be a powerful

tool for operations, and eliminating non-useful alarms

*originally published as ISA-18.2-2009, now also IEC-62682

Typical example of results of 18.2 being implemented (showing before/after)



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Alarm Management: ISA18.2

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ANSI/ISA-18.2-2016, Management of Alarm Systems for the Process Industries

-Addresses the development, design, installation, and management of alarm systems in the process industries

-Defines the terminology and models to develop an alarm system – and the work processes to effectively maintain it throughout its lifecycle

-Six technical reports available to explain specific applications in greater detail

-Based on work by the ISA18 committee, which has been active since 2003.

-First version of ISA18.2 standard published in 2009, became IEC-62682 in 2015, and updated version published in 2016.



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Alarm Management: ISA18.2 Alarm Mgmt. Lifecycle



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Alarm Management: Master Alarm Database

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• MADB

– Central repository of approved alarms and their

configuration

Tag Priority Desc. Condition Consequence

If Ignored

Consequence

Severity

Expected Operator

Response

Time to

Respond

P1-380-LAH-201 LOW Aeration

1 High

Level

High Level

Switch Activated

for 10sec

Overflows in

Secondary

clarifiers.

MINOR Check Level

Controller

2 hours

P1-380-AAL-102 MED Aeration

1 Low DO

DO below 3ppm

for 30min

Loss of Biological

Action, Risk of

Damage to

Biological Mass

MAJOR Investigate and

turn on additional

blowers

1 hour

P1-380-PALL-456A LOW Aeration

1 Air Pres.

Low Low

Less than 15psi

for 5min

Loss of Energy if Air

Leak, Poor

Aeration

(Note: there is a

low DO alarm)

MINOR Check pressures in

air distribution

system via HMI,

check valves in field

4 hrs



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Alarm Management: Master Alarm Database

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• Alarm Tag

• Alarm Description (full description & what is shown on HMI)

• Identification: Trigger Condition, Purpose

• Rationalization:

– Consequence & Severity if Ignored

– Expected Operator Response, Time to Respond

– Alarm Priority & Alarm Class

– Justification for having this alarm configured!

• Design: Trigger Condition, On/Off Delays, Additional Filtering Logic, Setpoints,

Routing/grouping information for the HMI

• Operation: When put into service, If Periodic Testing is required



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Alarm Management: Key SCADA Features

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• Master Alarm Database

• Ability to create non-alarm messages and logged events

• Support for Alerts, Prompts, and Maintenance Messages

• HMI Alarm Summary Display Screen

• Alarm Sorting, Filtering, Routing

• Alarm Areas/Grouping

• Alarm Priorities

• Alarm Classes



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Alarm Management: Key SCADA Features cont’d

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• Standardizing Alarm Features with Function Blocks

• On-Delay, Off-Delay, Deadband

• Conditional Alarming: base condition plus additional logic

• Alarm Shelving Method with Authorization / Logging

• Alarm Out of Service

• Change Control – Permissions, Setpoints, Configuration

• Configuration Change Logging

• Alarm Setpoint/Attribute verification & enforcement



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Alarm Management: Non-Alarms

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HMI: Alarms, Events and Notifications• SCADA Systems can have multiple types of notifications

• SCADA systems should have support for:

– Alarms

– Other notifications: alerts, prompts, maintenance messages

– Event messages

– Logged-only events



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Alarm Management: Dedicated Alarm Display

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• Dedicated screen for displays alarms – only alarms

• Ideally on its own dedicated monitor in multi-monitor setup

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Alarm Management: Programming Best Practices

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• Use a standardized function block in your PLC for all alarms

• Key Features:

– Raw Status vs. Alarm Bit

– Condition Inversion

– Logic-Based Suppression

– ON-Delay

– OFF-Delay

– Shelving / Out of Service support (if required at PLC-level)

• Additional Features for Analog/Value Alarms

– Deadband

– Alarm Masking if Signal is Bad

– Masking of Lesser Alarms (L vs. LL)

– Rate of Change

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Data Redundancy



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Data Redundancy: Logging Data

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• O.Reg. 170 requires us to log chlorine residuals every 5 minutes

• SCADA Systems are not perfect: unit failures and network outages do happen

• Best Practice is to have redundant data logging

– Main SCADA System logging data

– Data loggers at sites

• Existing Practice

– Redundant data loggers. Data must be gathered or imported manually into reporting system

– Custom programming often needed to implement backup data logging in PLCs

• New Developments

– New data loggers and operator terminals that do store/forward data logging

– Reporting systems and historians that can accept data from multiple sources

– Networking Protocols, e.g., DNP3, that have built-in time-stamping & store/forward logging



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Data Redundancy: Logging Data

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SCADA Network Redundancy



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• SCADA is critical to operations

– Data Logging,

– Situational Awareness,

– Remote Control by Operators,

– Automatic Control,

– Alarms,

– Reporting

• SCADA relies on its process control network to stay online

– In-plant Ethernet networks

– Wide Area Networks (WAN) to remote sites

• Without the SCADA network, the SCADA system cannot operate



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• O.Reg. 170 – Drinking Water Systems

• Free Chlorine Residuals Must be Logged Minimum Every 5 minutes

• Low chlorine alarms must be communicated promptly

• Very challenging to meet this uptime for a SCADA network

• SCADA system must be online 24/7, 365 days/year

• Less than 5 min downtime/year = 99.9995% uptime

• Most IT Systems only reach 95 to 99% uptime (outages at night ok)

• SCADA system has to be 10,000 X more reliable than an IT system



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• SCADA Network Technologies

– Fibre optic (public)*

– Fibre optic (MPLS)

– Fibre optic (utility owned)

– Cellular / Wireless*

– DSL (private or public)*

– Radios – licensed*

– Radios – unlicensed*

– Bell Lines

– Private Cables

– ?

*these approaches usually require extra VPN routers/firewalls be used



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SCADA Network Redundancy: One Solution



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Last of all: Cyber Security



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SCADA Cyber Security

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• You need to protect your SCADA system for unauthorized access

• In the past this was difficult to do

• Requires multipronged approach

– People

– Process

– Technology

• There is guidance now available on how to do this

– ISA/IEC-62443 (formerly known as ISA-99)

– AWWA GW430

– NIST Cyber Security Framework



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SCADA Cyber Security: ISA/IEC-62443

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SCADA Cyber Security: ISA/IEC-62443



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Wrapping Up

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• SCADA is essential for both Operations and Compliance

• Operators Need Situational Awareness to Operate Effectively

• Use the SCADA HMI to show the whole picture to operators

• SCADA Alarms systems must be rationalized/documented

• Pay attention to data integrity by investing in data redundancy

• SCADA networks are key to robust SCADA systems

• Cyber Security is requires a multi-pronged approach

• When upgrading SCADA systems, leverage what you have.

• Take advantage of new technology and ideas.



current trends in scada systems situational …...1 graham nasby, p.eng, pmp, cap water scada &...

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